TWI591682B - Methods and apparatuses for effectively reducing gas residence time in a plasma processing chamber - Google Patents
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- H—ELECTRICITY
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- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
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Description
本發明有關於有效地減少電漿處理腔室中氣體停留時間之方法及設備。 The present invention relates to a method and apparatus for effectively reducing gas residence time in a plasma processing chamber.
電漿已長期使用於將基板(例如,晶圓、平板顯示器、液晶顯示器及其他)處理成為電子裝置(例如,積體電路晶粒)以併入各種電子產品之中(例如,智慧型手機、電腦及其他)。 Plasma has long been used to process substrates (eg, wafers, flat panel displays, liquid crystal displays, and others) into electronic devices (eg, integrated circuit dies) for incorporation into a variety of electronic products (eg, smart phones, Computer and other).
在電漿處理中,具有一或更多電漿處理腔室之電漿處理系統可使用來處理一或更多基板。在每一腔室中,電漿產生可使用電容式耦合電漿技術、電感式耦合電漿技術、電子迴旋加速技術、微波技術等。 In plasma processing, a plasma processing system having one or more plasma processing chambers can be used to process one or more substrates. In each chamber, plasma generation can use capacitive coupled plasma technology, inductively coupled plasma technology, electron cyclotron technology, microwave technology, and the like.
在晶圓之處理的期間,例如釋放反應氣體(其可使用氣體之一或多種類型)進入電漿處理區域中並且賦予能量以形成電漿。例如,若使用電漿蝕刻基板的平面部分(相對於斜面部分),電漿係限制於電漿處理區域,該電漿處理區域集中在基板之上且一般以基板、上電極或上腔室壁/構件以及/或限制環組為界。然後使用電漿蝕刻、沉積,或以其他方式處理晶圓表面的曝露區域。 During processing of the wafer, for example, a reactive gas (which may use one or more types of gases) is introduced into the plasma processing zone and energized to form a plasma. For example, if a plasma is used to etch a planar portion of the substrate (relative to the bevel portion), the plasma is limited to the plasma processing region, which is concentrated over the substrate and generally with the substrate, the upper electrode, or the upper chamber wall. /Component and / or limit ring group is bounded. The plasma exposed surface is then etched, deposited, or otherwise treated using plasma.
處理期間,電漿與基板上曝露區域相互作用,其交互作用同時處理曝露區域並產生副產品。然後在電漿持續由所供應之反應氣體產生時,將副產品氣體抽離。電漿中的其他成分(離子或自由基)會形成對蝕刻結構的側壁保護至關重要的某些前驅物(pre-cursor)以確保非均向性的蝕刻。藉由舉例的方式,這樣的前驅體在特徵側壁上會導致聚合物沉積以改 善蝕刻方向性。其他前驅物會在不同材料的薄膜之間有利地導致某些蝕刻選擇性,其在其他情況下將會難以達成。 During processing, the plasma interacts with the exposed areas on the substrate, and the interaction simultaneously treats the exposed areas and produces by-products. The by-product gas is then withdrawn as the plasma continues to be produced from the supplied reaction gas. Other components (ion or free radicals) in the plasma form certain pre-cursors that are critical to the sidewall protection of the etched structure to ensure an anisotropic etch. By way of example, such precursors can cause polymer deposition on the feature sidewalls. Good etching direction. Other precursors can advantageously result in some etch selectivity between films of different materials, which would otherwise be difficult to achieve.
圖1顯示電漿處理系統(可具有一或更多腔室)中習知的電漿處理腔室102。在圖1中,基板104係顯示設置於形成下電極之靜電夾盤(ESC,electrostatic chuck)106上。絕緣環108及接地環110係顯示環繞ESC 106。顯示電漿處理區域120以腔室頂板122、下電極/ESC106以及一組限制環124為界。例如,在電容式耦合電漿處理系統的情況中,腔室頂板122可代表上電極。在其他的系統中,腔室頂板僅可代表用以限制電漿之腔室結構。 Figure 1 shows a conventional plasma processing chamber 102 in a plasma processing system (which may have one or more chambers). In FIG. 1, the substrate 104 is shown mounted on an electrostatic chuck (ESC) 106 forming a lower electrode. The insulating ring 108 and the grounding ring 110 are shown surrounding the ESC 106. The plasma processing region 120 is shown bounded by a chamber top plate 122, a lower electrode/ESC 106, and a set of confinement rings 124. For example, in the case of a capacitively coupled plasma processing system, the chamber top plate 122 can represent the upper electrode. In other systems, the chamber ceiling can only represent the chamber structure used to limit the plasma.
經由氣體充氣部130由外部的氣體供應器(習知且不顯示)供應反應氣體,其也可包含加熱設備以控制上電極122的溫度。在圖1的範例中,電漿處理腔室102係電容式耦合電漿腔室且因此腔室頂板122可代表上電極,其例如可接地或可具有射頻(RF)能量。 The reaction gas is supplied via an external gas supply (known and not shown) via the gas plenum 130, which may also include a heating device to control the temperature of the upper electrode 122. In the example of FIG. 1, the plasma processing chamber 102 is a capacitively coupled plasma chamber and thus the chamber top plate 122 can represent an upper electrode that can be grounded, for example, or can have radio frequency (RF) energy.
電漿產生電源170,在圖1的範例中為RF電源供應器的形式,在電漿處理區域120中供應RF能量給下電極/ESC 106以激起電漿。在其他腔室設計或使用不同電漿產生技術之腔室中,電漿產生電源170可包含多個電源以提供RF能量給腔室的不同構件或可為除了RF以外電漿產生技術的另一種類型(例如微波)。 The plasma generating power source 170, in the form of the RF power supply in the example of FIG. 1, supplies RF energy to the lower electrode/ESC 106 in the plasma processing region 120 to excite the plasma. In other chamber designs or chambers that use different plasma generation techniques, the plasma generating power source 170 can include multiple power sources to provide RF energy to different components of the chamber or can be another plasma generating technique other than RF. Type (eg microwave).
副產品氣體可通過腔室側邊或腔室下部或兩者進行排出。電漿處理腔室102的構件以及其他現存的電漿產生腔室(使用電容式耦合電漿或其他使用不同電漿產生技術所產生之電漿)對該領域技術者係習知且廣為人知,且在這裡將不詳細闡述。 By-product gases can be vented through the sides of the chamber or the lower portion of the chamber or both. The components of the plasma processing chamber 102, as well as other existing plasma generating chambers (using capacitively coupled plasma or other plasmas produced using different plasma generating techniques), are well known and well known to those skilled in the art, and It will not be elaborated here.
已觀察到在某些電漿處理腔室中,從基板104的中心區域150到基板105的邊緣區域152存在某種程度的製程非均勻性(就處理速率或處理結果而言)。當在狹窄間隙腔室中(狹窄間隙腔室表示在腔室中基板的上表面及上電極的下表面之間的間隙比基板直徑的10%還少)蝕刻以及/或處理較大的基板(如450mm或更大之晶圓)時,非均勻性的問題傾向於惡化。 It has been observed that in certain plasma processing chambers, there is some degree of process non-uniformity (in terms of processing rate or processing results) from the central region 150 of the substrate 104 to the edge region 152 of the substrate 105. When a narrow gap chamber is present (the narrow gap chamber indicates that the gap between the upper surface of the substrate and the lower surface of the upper electrode in the chamber is less than 10% of the diameter of the substrate) etching and/or processing a larger substrate ( For wafers such as 450 mm or larger, the problem of non-uniformity tends to deteriorate.
在某些情況中,高深寬比特徵的蝕刻易於遭受一稱為深寬比有關之蝕刻(ARDE,Aspect Ratio Dependent Etching)的現象。一些證據顯示,導致ARDE之一機制係為反應副產品耗費相對長時間以從深結構(諸如高深 寬比之孔(或凹槽))的下部份擴散出而到達它們可被抽離之晶圓表面。在深特徵底部蝕刻副產品的大量增加減慢了新蝕刻劑的重新供應從而減少它們的濃度。當蝕刻前緣推進至特徵部的較深處,上述狀況導致了蝕刻前緣的減慢(與遮罩正下方之速率相比)。 In some cases, etching of high aspect ratio features is susceptible to a phenomenon known as Aspect Ratio Dependent Etching (ARDE). Some evidence suggests that one of the mechanisms leading to ARDE is a reaction by-product that takes a relatively long time to move from deep structures (such as high depth) The lower portion of the hole (or groove) of the width ratio diffuses out to reach the surface of the wafer from which they can be drawn. The large increase in etch by-products at the bottom of the deep features slows the re-supply of new etchants to reduce their concentration. When the etch leading edge advances to a deeper portion of the feature, the above conditions result in a slowing of the etch leading edge (compared to the rate directly below the mask).
有鑑於以上的狀況,改良的蝕刻技術及設備是需要的。 In view of the above, improved etching techniques and equipment are needed.
在一實施例中,本發明關於用以處理基板之具有至少一電漿處理腔室的電漿處理系統。該電漿處理腔室包含用以支持基板的下電極以及設置於下電極之上之腔室頂板,俾使電漿處理區域在處理期間存在於基板上表面及腔室頂板之間。電漿處理系統也包含用以提供能量以在電漿處理區域中從所供應的反應氣體產生電漿的電漿產生電源、以及用以放射第一光線進入電漿處理區域的發光設備。更包含用以接收第二光的收光設備,第二光代表第一光的一已改變形式(在第一光通過電漿處理區域之後)。附加包含用以分析第二光的邏輯以確定第二光的參數是否等於或超出第一臨界值、或等於或落在第二臨界值之下,其中若第二光的參數等於或超出第一臨界值,則邏輯傳送第一訊號以減少由電漿產生電源所提供之電漿產生能量之量;若第二光的參數等於或落在第二臨界值之下,則邏輯傳送第二訊號以增加由電漿產生電源所提供之電漿產生能量之量。 In one embodiment, the present invention is directed to a plasma processing system having at least one plasma processing chamber for processing a substrate. The plasma processing chamber includes a lower electrode for supporting the substrate and a chamber top plate disposed above the lower electrode such that the plasma processing region is present between the upper surface of the substrate and the top plate of the chamber during processing. The plasma processing system also includes a plasma generating power source for providing energy to generate plasma from the supplied reactive gas in the plasma processing region, and a light emitting device for emitting the first light into the plasma processing region. There is further included a light collecting device for receiving the second light, the second light representing a changed form of the first light (after the first light passes through the plasma processing region). Additionally comprising logic to analyze the second light to determine whether the parameter of the second light is equal to or exceeds the first threshold, or equal to or falls below the second threshold, wherein if the parameter of the second light is equal to or exceeds the first a threshold value, the logic transmits a first signal to reduce the amount of energy generated by the plasma provided by the plasma generating power source; if the parameter of the second light is equal to or falls below the second threshold value, the logic transmits the second signal to Increasing the amount of energy produced by the plasma provided by the plasma generating power source.
在又另一個實施例中,本發明關於在具有至少一電漿處理腔室的電漿系統中處理基板的方法,腔室包含至少一用以支持基板的下電極、設置於下電極之上之腔室頂板(俾使電漿處理區域在處理期間存在於基板上表面及腔室頂板之間)、以及用來提供能量以在電漿處理區域中從所供應的反應氣體來產生電漿的電漿產生電源。該方法包含提供用以發射第一光線入電漿處理區域的發光設備以及用以接收第二光的收光設備,第二光代表第一光的一已改變形式(在第一光通過電漿處理區域之後),也包含用以分析第二光的邏輯以確定第二光的參數是否超出第一臨界值或落在第二臨界值之下。若第二光的參數等於或超出第一臨界值,則該方法減少由電漿產生電源所提供之電漿產生能量之量。若第二光線的參數等於或落在第二臨界值之下,則該方法增加由電漿產生電源所提供之電漿產生能量之量。 In still another embodiment, the present invention is directed to a method of processing a substrate in a plasma system having at least one plasma processing chamber, the chamber including at least one lower electrode for supporting the substrate, disposed over the lower electrode The chamber top plate (which causes the plasma processing region to exist between the upper surface of the substrate and the top plate of the chamber during processing) and the electricity used to provide energy to generate plasma from the supplied reactive gas in the plasma processing region The pulp produces a power source. The method includes providing a light emitting device for emitting a first light into a plasma processing region and a light collecting device for receiving a second light, the second light representing a changed form of the first light (processing the first light through the plasma After the region, logic is also included to analyze the second light to determine if the parameter of the second light exceeds the first threshold or falls below the second threshold. If the parameter of the second light is equal to or exceeds the first critical value, the method reduces the amount of energy generated by the plasma provided by the plasma generating power source. If the parameter of the second ray is equal to or falls below the second threshold, the method increases the amount of energy produced by the plasma provided by the plasma generating power source.
102‧‧‧電漿處理腔室 102‧‧‧The plasma processing chamber
104‧‧‧基板 104‧‧‧Substrate
106‧‧‧靜電夾盤 106‧‧‧Electrical chuck
108‧‧‧絕緣環 108‧‧‧Insulation ring
110‧‧‧接地環 110‧‧‧ Grounding ring
120‧‧‧電漿處理區域 120‧‧‧ Plasma processing area
122‧‧‧腔室頂板 122‧‧‧Case ceiling
124‧‧‧限制環 124‧‧‧Restricted ring
130‧‧‧氣體充氣部 130‧‧‧Gas Inflator
150‧‧‧基板中心區域 150‧‧‧Substrate center area
152‧‧‧基板邊緣區域 152‧‧‧Surface edge area
170‧‧‧電漿產生電源 170‧‧‧ Plasma generated power
204‧‧‧電漿處理腔室 204‧‧‧The plasma processing chamber
206‧‧‧下電極 206‧‧‧ lower electrode
208‧‧‧基板 208‧‧‧Substrate
210‧‧‧腔室頂板 210‧‧‧Cable ceiling
212‧‧‧電漿處理區域 212‧‧‧The plasma processing area
214‧‧‧發光設備 214‧‧‧Lighting equipment
220‧‧‧收光設備 220‧‧‧Lighting equipment
222‧‧‧透鏡 222‧‧‧ lens
240‧‧‧RF電源供應器 240‧‧‧RF power supply
280‧‧‧控制器 280‧‧‧ Controller
304‧‧‧電漿處理腔室 304‧‧‧The plasma processing chamber
306‧‧‧下電極 306‧‧‧ lower electrode
308‧‧‧基板 308‧‧‧Substrate
310‧‧‧腔室頂板 310‧‧‧Case ceiling
312‧‧‧電漿處理區域 312‧‧‧ Plasma processing area
328‧‧‧光二極體 328‧‧‧Light diode
330‧‧‧干涉濾波器 330‧‧‧Interference filter
340‧‧‧RF電源供應器 340‧‧‧RF power supply
402‧‧‧訊號強度 402‧‧‧Signal strength
420‧‧‧臨界值 420‧‧‧critical value
430‧‧‧臨界值 430‧‧‧critical value
本發明係藉由舉例且不是藉由限制的方式說明於附圖的圖中,並且其中類似的參考數字指的是同樣的元件且其中:圖1顯示在電漿處理系統(其可具有一或更多腔室)中一習知之電漿處理腔室以方便討論。 The present invention is illustrated by the accompanying drawings in the drawings, and the More chambers) a conventional plasma processing chamber for ease of discussion.
根據本發明之實施例,圖2顯示用以減少有效氣體停留時間以改善均勻性的發明腔室之一部分的簡化圖。 2 shows a simplified diagram of a portion of an inventive chamber to reduce effective gas residence time to improve uniformity, in accordance with an embodiment of the present invention.
根據本發明之實施例,圖3顯示用以減少有效氣體停留時間以改善均勻性的發明腔室之一部分的簡化圖。 In accordance with an embodiment of the present invention, FIG. 3 shows a simplified diagram of a portion of an inventive chamber to reduce effective gas residence time to improve uniformity.
根據本發明之實施例,圖4顯示螢光或吸收之訊號強度作為時間之函數的圖。 Figure 4 shows a plot of fluorescence or absorbed signal intensity as a function of time, in accordance with an embodiment of the present invention.
根據本發明之實施例,圖5顯示訊號強度對螢光(在一雷射光束從發光設備發射並由收光設備接收後所放射)波長的圖。 In accordance with an embodiment of the present invention, FIG. 5 shows a graph of the wavelength of the signal intensity versus fluorescence (which is emitted after a laser beam is emitted from the illumination device and received by the light-receiving device).
根據本發明之實施例,圖6顯示訊號強度對透射光(在一寬(白)光譜光束從發光設備發射且由收光設備接收後並穿過吸收介質之後)波長的圖。 In accordance with an embodiment of the present invention, FIG. 6 shows a plot of signal intensity versus transmitted light (after a wide (white) spectral beam is emitted from the illumination device and received by the light-receiving device and after passing through the absorption medium).
根據本發明之實施例,圖7顯示用以減少氣體的有效停留時間以改善均勻性之方法。 In accordance with an embodiment of the present invention, Figure 7 shows a method for reducing the effective residence time of a gas to improve uniformity.
本發明現藉由參照附圖中所顯示的其若干實施例來詳細地加以描述。以下的說明中,敘述許多細節以提供對本發明之透徹的理解。然而,對熟悉該領域者顯而易見:本發明可在沒有這些特定細節之一些或所有者的情況下實施。在其他情況下,為人所熟知的製程步驟及/或結構不詳細地描述以免不必要地混淆本發明。 The invention will now be described in detail by reference to a few embodiments thereof illustrated in the drawings. In the following description, numerous details are set forth to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without some of the specific details. In other instances, well-known process steps and/or structures are not described in detail to avoid unnecessarily obscuring the invention.
下文描述不同之實施例,包含方法及技術。應牢記本發明也涵蓋製品,該製品包含其上儲存執行本發明技術實施例的電腦可讀取指令之電腦可讀取媒體。該電腦可讀取媒體可包括例如半導體、磁性、光磁性、光學性或其他形式之用以儲存電腦可讀取代碼的電腦可讀取媒體。再者, 本發明也涵蓋了用以實施本發明實施例的設備。這樣的設備可包含專用的及/或可程式化的電路,以執行與本發明實施例有關的任務。這種設備的例子包括通用電腦及/或專用計算裝置(當適當地程式化時),並可能包括用於關於本發明實施例之各種任務的電腦/計算裝置以及專用的/可程式化電路的組合。 Different embodiments are described below, including methods and techniques. It should be borne in mind that the present invention also encompasses an article comprising a computer readable medium having stored thereon computer readable instructions for performing embodiments of the present technology. The computer readable medium can include, for example, a semiconductor, magnetic, photomagnetic, optical, or other form of computer readable medium for storing computer readable code. Furthermore, The invention also encompasses an apparatus for practicing embodiments of the invention. Such devices may include dedicated and/or programmable circuitry to perform the tasks associated with embodiments of the present invention. Examples of such devices include general purpose computers and/or special purpose computing devices (when properly programmed), and may include computer/computing devices and dedicated/programmable circuits for various tasks related to embodiments of the present invention. combination.
本發明之實施例關於在電漿處理腔室中用以控制電漿產生俾減少副產品氣體於電漿處理腔室中的有效停留時間之方法及設備。有效停留時間可定義為在電漿處於「蝕刻」狀態下(例如,根據正常的蝕刻配方),氣體/電漿成分存在於基板上的平均時間。本發明的實施例試圖減少有效停留時間,其係藉由RF功率調變以將電漿蝕刻狀態持續時間減少到,例如,比電漿/氣體成分物理性地從晶圓之上移動到晶圓外面的區域所需之時間更短的時間。例如,對一給定的腔室若正常的(先前的技術配方)氣體停留時間是20毫秒,以及根據本發一實施例,射頻(RF)供電時間僅是20毫秒中的5毫秒,有效停留時間可粗略地視為是5毫秒,其大約是20毫秒的25%。 Embodiments of the present invention are directed to methods and apparatus for controlling plasma generation in a plasma processing chamber to reduce the effective residence time of by-product gases in a plasma processing chamber. The effective residence time can be defined as the average time that the gas/plasma composition is present on the substrate while the plasma is in an "etched" state (eg, according to a normal etch recipe). Embodiments of the present invention seek to reduce the effective dwell time by RF power modulation to reduce the plasma etch state duration to, for example, physically move from above the wafer to the wafer than the plasma/gas component The outer area takes less time. For example, if a given chamber has a normal (previous technical formulation) gas residence time of 20 milliseconds, and according to an embodiment of the invention, the radio frequency (RF) power supply time is only 5 milliseconds in 20 milliseconds, effectively staying The time can be roughly considered to be 5 milliseconds, which is about 25% of 20 milliseconds.
關於非均勻性的問題,在此發明人推論:相對於存在於基板中心的副產品氣體濃度,副產品氣體濃度會朝基板的邊緣增加。這是因為在大多數的腔室中,副產品氣體在經由腔室側邊或腔室下部或兩者被排出之前係從基板的中心朝基板邊緣移動。基板的不同區域上之副產品氣體濃度的差異可能是製程非均勻性的一個貢獻因素。 Regarding the problem of non-uniformity, the inventors conclude that the by-product gas concentration increases toward the edge of the substrate relative to the concentration of by-product gas present at the center of the substrate. This is because in most chambers, by-product gases move from the center of the substrate toward the edge of the substrate before being discharged through the side of the chamber or the lower portion of the chamber or both. The difference in by-product gas concentration across different regions of the substrate may be a contributing factor to process non-uniformity.
減少氣體停留時間(也就是,在氣體被排出之前停留在腔室中的時間)可改善製程均勻性(其可涉及蝕刻均勻性、沉積均勻性、蝕刻率均勻性、沉積率均勻性、蝕刻深度均勻性以及/或沉積厚度均勻性,取決於所包含之處理的類型)。如一般所知,氣體停留時間與基板上之電漿體積、排氣泵裝置之抽速以及製程氣體壓力有關。氣體停留時間所能減少之量存在著下限,因為例如對某一抽速及壓力而言,電漿體積不能無限制地減少。 Reducing gas residence time (i.e., time to stay in the chamber before the gas is expelled) can improve process uniformity (which can involve etch uniformity, deposition uniformity, etch rate uniformity, deposition rate uniformity, etch depth) Uniformity and/or deposition thickness uniformity, depending on the type of treatment involved. As is generally known, the gas residence time is related to the volume of the plasma on the substrate, the pumping speed of the exhaust pump unit, and the process gas pressure. There is a lower limit to the amount by which the gas residence time can be reduced, because for example, for a certain pumping speed and pressure, the plasma volume cannot be reduced without limitation.
根據本發明的一或更多實施例,藉由減少對處理時間之至少一部份的電漿反應而「有效地」減少氣體停留時間。如在此所使用的術語,處理時間意指根據一給定的配方處理基板所需的時間。根據本發明之一或更多實施例,電漿處理腔室係根據所提供之處理配方在一部分之處理時間持續期間以正常的處理模式操作。對於處理時間持續期間之另一部分,電 漿處理腔室以「減少」模式操作,藉此減少電漿產生能量(RF或微波或電漿產生能量的其他形式),以減少或停止與基板曝露區域的反應。 In accordance with one or more embodiments of the present invention, the gas residence time is "effectively" reduced by reducing plasma reactions to at least a portion of the processing time. As the term is used herein, processing time means the time required to process a substrate according to a given formulation. In accordance with one or more embodiments of the present invention, the plasma processing chamber operates in a normal processing mode for a portion of the processing time duration in accordance with the processing recipe provided. For another part of the processing time duration, electricity The slurry processing chamber operates in a "decrease" mode, thereby reducing the plasma generating energy (RF or microwave or other forms of energy generated by the plasma) to reduce or stop the reaction with the substrate exposed areas.
或者,根據本發明的一或更多實施例,藉由減少對「真實」氣體停留時間之至少一部份的電漿反應而「有效地」減少氣體停留時間。如在此所使用的術語,「真實」氣體停留時間意指氣體在腔室中真正花的時間且關於腔室容留氣體(其因此與氣體壓力及體積有關)之體積除以氣體自腔室中移除之速率的比率。根據本發明的一或更多實施例,電漿處理腔室係根據所提供的處理配方在一部分之真實氣體停留時間持續期間以正常的處理狀態操作。對於真實氣體停留時間持續期間之另一部分,電漿處理腔室以「減少」模式操作,藉此減少電漿產生能量(RF或微波或電漿產生能量的其他形式),以減少或停止與基板曝露區域的反應。 Alternatively, in accordance with one or more embodiments of the present invention, the gas residence time is "effectively" reduced by reducing plasma reactions to at least a portion of the "true" gas residence time. As used herein, the term "real" gas residence time means the time that the gas actually spends in the chamber and the volume of gas contained in the chamber (which is therefore related to gas pressure and volume) divided by the gas in the chamber. The rate of removal rate. In accordance with one or more embodiments of the present invention, the plasma processing chamber operates in a normal processing state for a portion of the true gas residence time duration in accordance with the provided processing recipe. For another portion of the true gas residence time duration, the plasma processing chamber operates in a "decrease" mode, thereby reducing the plasma generating energy (RF or microwave or other forms of energy generated by the plasma) to reduce or stop the substrate The reaction in the exposed area.
在「減少」模式時間的期間,反應副產品氣體朝基板邊緣移動,且並不顯著地進行與基板曝露部分的二次反應。一旦減少模式時間結束,電漿產生能量又再次增加以於完整層級處理基板。在一或更多實施例中,在「減少模式」時間期間,流進腔室中的反應氣體維持不變。在一或更多實施例中,間隔長度的範圍可介於1msec到蝕刻步驟的全長之間。 During the "decrease" mode time, the reaction by-product gas moves toward the edge of the substrate, and the secondary reaction with the exposed portion of the substrate is not significantly performed. Once the mode time is reduced, the plasma generating energy is again increased to process the substrate in a full level. In one or more embodiments, the reactive gas flowing into the chamber remains unchanged during the "reduce mode" time. In one or more embodiments, the length of the interval can range from 1 msec to the full length of the etching step.
在一或更多實施例中,積極地監控電漿以控制減少模式的開始與終止。在一或更多實施例中,使用發光設備發射光進入電漿處理區域並監控橫越穿過電漿處理區域之後的已改變光。例如,光可藉由使其某部分之波長被吸收而改變。例如,光可藉由發出螢光而改變。不管如何,係監控已改變光並與做為波長函數之兩個臨界值作比較。 In one or more embodiments, the plasma is actively monitored to control the start and end of the reduced mode. In one or more embodiments, the illuminating device is used to emit light into the plasma processing region and to monitor the changed light across the plasma processing region. For example, light can be changed by absorbing a certain portion of its wavelength. For example, light can be changed by emitting fluorescent light. Regardless, the system monitors the changed light and compares it to two threshold values as a function of wavelength.
若參數(舉例,例如被吸收波長的強度或放射螢光波長的強度)等於或超出第一臨界值,控制電漿以進入減少模式。一旦在減少模式中,減少或停止反應並隨著時間的推移減少副產品氣體濃度。若參數等於或在第二臨界值之下,控制電漿以退出減少模式。在跳出減少模式之後,例如反應會增加回至完整層級。在本發明實施例的上下文中,減少模式指的是與正常蝕刻模式相比較之較低的射頻功率位準並可能包含電漿關閉狀態。根據本發明的一實施例,例如,為了避免關聯於電漿重新點燃及穩定的複雜性及延遲,在減少模式期間大大地減少電漿但不完全將其熄滅。根據本發明的另一實施例,做為另一個例子,在減少模式期間可關閉電漿。 If the parameter (for example, the intensity of the absorbed wavelength or the intensity of the emitted fluorescent wavelength) equals or exceeds the first critical value, the plasma is controlled to enter the reduced mode. Once in the reduction mode, the reaction is reduced or stopped and the by-product gas concentration is reduced over time. If the parameter is equal to or below the second threshold, the plasma is controlled to exit the reduced mode. After jumping out of the reduction mode, for example, the reaction will increase back to the full level. In the context of embodiments of the invention, the reduced mode refers to a lower RF power level compared to the normal etch mode and may include a plasma off state. In accordance with an embodiment of the present invention, for example, to avoid the complexity and delay associated with plasma reignition and stabilization, the plasma is greatly reduced during the mode reduction but is not completely extinguished. According to another embodiment of the invention, as another example, the plasma can be turned off during the mode reduction.
本發明之特徵及優點參照以下的圖式及討論可更獲得理解。 The features and advantages of the present invention will be more fully understood from the following description and description.
根據本發明的一實施例,圖2顯示用以減少有效氣體停留時間以改善均勻性之發明腔室一部分的簡化圖。參考圖2,具有至少一電漿處理腔室204之電漿處理系統包含在處理期間用來支持基板208的下電極206。腔室頂板210,例如其代表電容式耦合電漿處理腔室的案例中的上電極,或電感式耦合電漿處理腔室的案例中的介電窗,形成電漿處理區域212的上邊界。發光設備214(例如為具有平行光管之光源形式)發射光穿過電漿處理區域212。發射光可為單色的(例如,雷射)或可為寬頻帶。當光橫過電漿處理區域212時,光通過電漿及/或氣體及/或存在於電漿處理區域212中的物質且被改變。該改變光藉由收光設備220而接收,圖2之範例中收光設備220代表一光學發射光譜儀(OES)。可提供透鏡222以將已改變光聚焦於OES感測器上。 In accordance with an embodiment of the present invention, FIG. 2 shows a simplified diagram of a portion of an inventive chamber for reducing effective gas residence time to improve uniformity. Referring to FIG. 2, a plasma processing system having at least one plasma processing chamber 204 includes a lower electrode 206 for supporting a substrate 208 during processing. The chamber top plate 210, for example, the upper electrode in the case of a capacitively coupled plasma processing chamber, or the dielectric window in the case of an inductively coupled plasma processing chamber, forms the upper boundary of the plasma processing region 212. Light emitting device 214 (eg, in the form of a light source having a collimator) emits light through plasma processing region 212. The emitted light can be monochromatic (eg, laser) or can be broadband. As the light traverses the plasma processing zone 212, the light passes through the plasma and/or gas and/or materials present in the plasma processing zone 212 and is altered. The altered light is received by the light-receiving device 220. In the example of Figure 2, the light-receiving device 220 represents an optical emission spectrometer (OES). A lens 222 can be provided to focus the changed light onto the OES sensor.
收光設備220可包含一分析子單元,其對已改變光的參數(例如,被吸收波長的強度或放射螢光波長的強度)及兩個臨界值進行比較並提供回應於分析結果的訊號。若參數(舉例,例如被吸收波長的強度或放射螢光波長的強度)等於或超出第一臨界值,則藉由控制器280(其與收光設備220通訊且可能與收光設備220整合或可能是一單獨的元件)傳送一訊號給RF電源供應器240(在圖2的範例中代表電漿產生電源)以控制電漿(例如減少RF功率)以進入減少模式。一旦在減少模式中,減少或停止反應並隨著時間推移減少副產品氣體濃度。若參數等於或在第二臨界值之下,藉由控制器280傳送另一訊號給RF電源供應器240以控制電漿(例如增加RF功率)以跳出減少模式。跳出減少模式之後,例如反應會回增至完整層級。 Light-receiving device 220 can include an analysis sub-unit that compares parameters of the changed light (eg, the intensity of the absorbed wavelength or the intensity of the emitted fluorescent wavelength) and two thresholds and provides a signal responsive to the analysis. If the parameter (for example, the intensity of the absorbed wavelength or the intensity of the emitted fluorescent wavelength) is equal to or exceeds the first critical value, it is communicated by the controller 280 (which is in communication with the light-receiving device 220 and may be integrated with the light-receiving device 220 or It may be a separate component that transmits a signal to the RF power supply 240 (representing the plasma generating power in the example of Figure 2) to control the plasma (e.g., reduce RF power) to enter the reduced mode. Once in the reduction mode, the reaction is reduced or stopped and the by-product gas concentration is reduced over time. If the parameter is equal to or below the second threshold, another signal is sent to the RF power supply 240 by the controller 280 to control the plasma (e.g., increase RF power) to jump out of the reduced mode. After jumping out of the reduction mode, for example, the reaction will increase back to the full level.
根據本發明的一實施例,圖3顯示用以減少有效氣體停留時間以改善均勻性之發明腔室一部分的簡化圖。參考圖3,具有至少一電漿處理腔室304之電漿處理系統包含在處理期間用來支持基板308的下電極306。腔室頂板310,例如其代表電容式耦合電漿處理腔室的案例中的上電極,或電感式耦合電漿處理腔室的案例中的介電窗,形成電漿處理區域312的上邊界。發光設備(例如為具有平行光管之光源形式)發射光穿過電漿處理區域312。發射光可為單色的(例如,雷射)或可為寬頻帶。 In accordance with an embodiment of the present invention, FIG. 3 shows a simplified diagram of a portion of an inventive chamber to reduce effective gas residence time to improve uniformity. Referring to FIG. 3, a plasma processing system having at least one plasma processing chamber 304 includes a lower electrode 306 for supporting a substrate 308 during processing. The chamber top plate 310, for example, the upper electrode in the case of a capacitively coupled plasma processing chamber, or the dielectric window in the case of an inductively coupled plasma processing chamber, forms the upper boundary of the plasma processing region 312. Light emitting devices (eg, in the form of light sources having parallel light pipes) emit light through the plasma processing region 312. The emitted light can be monochromatic (eg, laser) or can be broadband.
當光橫過電漿處理區域312時,光通過電漿及/或氣體及/或 存在於電漿處理區域312中的物質且被改變。該改變光藉由收光設備接收,圖3之範例中收光設備代表一光二極體328以及一干涉濾波器330。 When light traverses the plasma processing zone 312, the light passes through the plasma and/or gas and/or The material present in the plasma processing zone 312 is altered. The change light is received by the light-receiving device. In the example of FIG. 3, the light-receiving device represents a photodiode 328 and an interference filter 330.
收光設備可包含一分析子單元,其對已改變光的參數(例如,被吸收波長的強度或放射螢光波長的強度)及兩個臨界值進行比較並提供回應於分析結果的訊號。若參數(舉例,例如被吸收波長的強度或放射螢光波長的強度)等於或超出第一臨界值,則傳送(使用例如圖2所描述之控制器)訊號給RF電源供應器340(在圖3的範例中代表電漿產生電源)以控制電漿(例如減少RF功率)以進入減少模式。一旦在減少模式中,減少或停止反應並隨著時間推移減少副產品氣體濃度。若參數等於或在第二臨界值之下,傳送另一訊號給RF電源供應器340以控制電漿(例如增加RF功率)以跳出減少模式。跳出減少模式之後,例如反應會回增至完整層級。 The light-receiving device can include an analysis sub-unit that compares parameters of the changed light (eg, the intensity of the absorbed wavelength or the intensity of the emitted fluorescent wavelength) and the two thresholds and provides a signal responsive to the analysis. If the parameter (for example, the intensity of the absorbed wavelength or the intensity of the emitted fluorescent wavelength) is equal to or exceeds the first critical value, then transmitting (using a controller such as that described in FIG. 2) to the RF power supply 340 (in the figure) The example of 3 represents plasma generation of power) to control the plasma (eg, reduce RF power) to enter a reduced mode. Once in the reduction mode, the reaction is reduced or stopped and the by-product gas concentration is reduced over time. If the parameter is equal to or below the second threshold, another signal is sent to the RF power supply 340 to control the plasma (e.g., increase RF power) to jump out of the reduced mode. After jumping out of the reduction mode, for example, the reaction will increase back to the full level.
根據本發明一實施例,圖4顯示作為時間函數之螢光或吸收的訊號強度圖。在時間T1期間,電漿處理腔室操作在正常模式且於完整層級進行處理。監控訊號強度402且若訊號強度402等於或超出臨界值420,藉由改變RF功率控制電漿以進入減少模式。減少模式持續期間顯示如時間T2。繼續監控訊號強度402且若訊號強度402等於或落在臨界值430之下,藉由改變RF功率控制電漿以跳出減少模式。在圖4的範例中,跳出減少模式之後,電漿處理回復到完整層級。在一或多個實施例中,於時間T1及T2期間,反應氣體進入腔室的流率保持為常數。 In accordance with an embodiment of the invention, Figure 4 shows a graph of fluorescence intensity or absorption as a function of time. During time T1, the plasma processing chamber operates in normal mode and is processed at the full level. The signal strength 402 is monitored and if the signal strength 402 equals or exceeds the threshold 420, the plasma is controlled to change into the reduced mode by varying the RF power. The reduction mode duration is displayed as time T2. Continuing to monitor the signal strength 402 and if the signal strength 402 is equal to or falls below the threshold 430, the plasma is controlled to change the RF power to jump out of the reduced mode. In the example of Figure 4, after the bounce reduction mode, the plasma processing returns to the full level. In one or more embodiments, the flow rate of reactant gases entering the chamber remains constant during times T1 and T2.
根據本發明一實施例,圖5顯示訊號強度對螢光(在從發光設備發射雷射光束並由收光設備接收之後所放射)波長的圖。如圖5所視,帶有波長WL之雷射使電漿處理區域中副產品氣體的某些氣體發射帶有波長W1之螢光。藉由監控螢光的強度,副產品氣體的濃度可加以約略估計或計算並在較早所討論的方式中與兩臨界值進行比較。 In accordance with an embodiment of the present invention, FIG. 5 shows a graph of the wavelength of the signal intensity versus fluorescence (which is emitted after the laser beam is emitted from the illumination device and received by the light-receiving device). As seen in Figure 5, a laser with a wavelength WL emits some of the gas of the by-product gas in the plasma processing zone with a fluorescent light of wavelength W1. By monitoring the intensity of the fluorescence, the concentration of by-product gas can be approximated or calculated and compared to the two thresholds in the manner discussed earlier.
根據本發明一實施例,圖6顯示訊號強度對被吸收光(在寬(白)光譜光束從發光設備發射並由收光設備吸收之後所放射)波長的圖。如同圖6所視,副產品氣體吸收白光譜的波長WS之某些部分。藉由監控在波長WS吸收多少光,副產品氣體濃度可加以約略估計或計算並在較早所討論的方式中與兩臨界值進行比較。 In accordance with an embodiment of the present invention, FIG. 6 shows a plot of signal intensity versus wavelength of absorbed light (after the wide (white) spectral beam is emitted from the illumination device and absorbed by the light-receiving device). As seen in Figure 6, the by-product gas absorbs some portions of the wavelength WS of the white spectrum. By monitoring how much light is absorbed at the wavelength WS, the byproduct gas concentration can be approximated or calculated and compared to the two thresholds in the manner discussed earlier.
根據本發明一實施例,圖7顯示用以減少氣體的有效停留時 間以改善均勻性之方法。該方法係實施於具有至少一電漿處理腔室的電漿系統中。該腔室包含至少一用以支持基板的下電極以及設置在下電極之上的腔室頂板,以使電漿處理區域在處理期間存在於基板的上表面以及腔室頂板之間。 Figure 7 shows an example of reducing the effective residence time of a gas according to an embodiment of the invention. To improve the uniformity. The method is practiced in a plasma system having at least one plasma processing chamber. The chamber includes at least one lower electrode for supporting the substrate and a chamber top plate disposed above the lower electrode such that the plasma processing region is present between the upper surface of the substrate and the chamber top plate during processing.
電漿處理腔室也包含用以提供能量之電漿產生電源,以在電漿處理區域中從所供應的反應氣體產生電漿。在步驟702中,提供一用以發射第一光進入該電漿處理區域的發光設備。在步驟704中,提供一用以接收第二光的收光設備,第二光代表該第一光的一已改變形式(在第一光通過該電漿處理區域之後)。在步驟706中,提供一用以分析第二光的邏輯以確定第二光的參數是否超出第一臨界值或落在第二臨界值之下。若第二光的參數等於或超出第一臨界值(712),步驟708包含減少由該電漿產生電源所提供之電漿產生能量之量。若不是(步驟712),程序回到步驟702以繼續監控該發射光。 The plasma processing chamber also includes a plasma generating power source for providing energy to generate plasma from the supplied reactive gas in the plasma processing zone. In step 702, a light emitting device for emitting first light into the plasma processing region is provided. In step 704, a light harvesting device is provided for receiving the second light, the second light representing a changed form of the first light (after the first light passes through the plasma processing region). In step 706, a logic is provided for analyzing the second light to determine if the parameter of the second light exceeds a first threshold or falls below a second threshold. If the parameter of the second light is equal to or exceeds the first threshold (712), step 708 includes reducing the amount of energy produced by the plasma provided by the plasma. If not (step 712), the program returns to step 702 to continue monitoring the emitted light.
若第二光的參數等於或落在第二臨界值(714)之下。步驟710包含增加由該電漿產生電源所提供的電漿產生能量之該量。若不是(步驟714),程序回到步驟702以繼續監控該發射光。圖7的步驟可反覆地執行(箭頭720)直到完成基板處理。 If the parameter of the second light is equal to or falls below the second critical value (714). Step 710 includes increasing the amount of energy produced by the plasma provided by the plasma generating power source. If not (step 714), the program returns to step 702 to continue monitoring the emitted light. The steps of Figure 7 can be performed repeatedly (arrow 720) until the substrate processing is completed.
從前面的敘述可以理解,本發明的實施例藉由有效地減少氣體停留時間改善均勻性。若調變RF電源以進入或跳出減少模式,在減少模式及全處理模式之間的調變可能在毫秒的範圍中,其傾向太長而不會顯著地影響電子溫度。然而,可以先前尚無法達成的程度(因減少腔室壓力、腔室體積的限制或增加抽氣速率的限制)而減少有效氣體停留時間。藉著減少有效氣體停留時間,有利地改善均勻性。 As can be appreciated from the foregoing description, embodiments of the present invention improve uniformity by effectively reducing gas residence time. If the RF power supply is modulated to enter or exit the reduced mode, the modulation between the reduced mode and the full processing mode may be in the range of milliseconds, which tends to be too long without significantly affecting the electronic temperature. However, the effective gas residence time can be reduced to the extent that has not previously been achieved (by reducing chamber pressure, chamber volume limitations, or increasing the rate of pumping rate). By reducing the effective gas residence time, the uniformity is advantageously improved.
雖然在此處之範例已在減少起因於基板的邊緣區域及基板的中心區域之間副產品濃度差別之非均勻性的背景中加以討論,但本發明的實施例可適用於監控反應副產品濃度或前驅體濃度並調變RF功率於正常及減少模式之間以減少它們的有效停留時間。 Although the examples herein have been discussed in the context of reducing non-uniformities in the difference in by-product concentration between the edge regions of the substrate and the central region of the substrate, embodiments of the present invention are applicable to monitoring reaction by-product concentrations or precursors. Body concentration and modulation of RF power between normal and reduced modes to reduce their effective residence time.
例如,為了影響聚合物沉積的量,可監控聚合物前驅物濃度以控制正常及減少模式(例如持續時間或RF功率位準)的參數。如所知的,某些蝕刻製程可能牽涉到沉積及蝕刻機制/子步驟之的平衡以達成所想要的 蝕刻結果。在這些蝕刻應用中,需要控制聚合物沉積因為,例如太多或太小的聚合物沉積可能會導致諸如減少的蝕刻率、非均勻性、有缺陷的蝕刻外型及其他不想要的結果。可選擇地或附加地,以上所討論之本發明的實施例可適用於監控前驅物的濃度並調變正常操作時間以及減少模式時間的持續時間及/或RF功率位準以提供用以控制蝕刻之額外的控制手段。 For example, to affect the amount of polymer deposition, the polymer precursor concentration can be monitored to control parameters of normal and reduced modes (eg, duration or RF power level). As is known, certain etching processes may involve balancing the deposition and etching mechanisms/substeps to achieve the desired Etching results. In these etching applications, it is desirable to control polymer deposition because, for example, too much or too little polymer deposition can result in, for example, reduced etch rates, non-uniformities, defective etch profiles, and other undesirable results. Alternatively or additionally, embodiments of the invention discussed above may be adapted to monitor the concentration of precursors and to modulate normal operating time and to reduce the duration of mode time and/or RF power levels to provide for controlled etching. Additional control means.
再者,在蝕刻基板的同時控制聚合物前驅物或副產品濃度以快速回應感測器量測結果的能力也可解決先前所提的深寬比有關之蝕刻(ARDE)問題。例如,在減少模式操作週期或脈波期間藉由給予蝕刻副產品更多時間以擴散出較高的深寬比特徵,在這些高深寬比的孔及凹槽中之蝕刻副產品的濃度可較好控制,從而減輕ARDE。 Furthermore, the ability to control the concentration of polymer precursors or by-products while etching the substrate to quickly respond to sensor measurements can also address the previously described aspect ratio related etch (ARDE) issues. For example, the concentration of etching by-products in these high aspect ratio holes and grooves can be better controlled by giving etch byproducts more time to diffuse higher aspect ratio characteristics during reduced mode operation periods or pulse waves. , thereby mitigating ARDE.
雖然本發明已透過幾個較佳的實施例描述,但仍有落於本發明之範圍內的的變化、置換及等效者。雖然在此提供了不同的範例,但意圖使這些範例相關於本發明為說明性而非限制性。並且,發明名稱及發明內容係為求方便而在此提供,且不應被用來解釋為此處之請求項的範圍。再者,摘要係以高度縮寫之行是寫成,並係為求方便而在此提供,且因此不應被用來解釋或限制表明於申請專利範圍中之整個發明。若在此使用術語「組」,此術語目的在使其一般被理解之數學意義涵蓋零、一、或大於一者。也應注意有很多實施本發明之方法及設備的替代性方式。因此欲將以下所附之請求項解釋為將所有此變化、置換及等效者包含為落在本發明之真實精神及範圍內。 While the invention has been described in terms of several preferred embodiments, the modifications and The various examples are provided herein, but are intended to be illustrative and not restrictive. Also, the names of the invention and the summary of the invention are provided herein for convenience and should not be construed as a limitation of the scope of the claims. In addition, the abstract is written in a highly abbreviated form and is provided here for convenience, and therefore should not be used to interpret or limit the entire invention indicated in the scope of the patent application. If the term "group" is used herein, the term is intended to encompass a mathematical meaning that is generally understood to encompass zero, one, or greater than one. It should also be noted that there are many alternative ways of implementing the methods and apparatus of the present invention. It is therefore intended that the appended claims be construed as being
204‧‧‧電漿處理腔室 204‧‧‧The plasma processing chamber
206‧‧‧下電極 206‧‧‧ lower electrode
208‧‧‧基板 208‧‧‧Substrate
210‧‧‧腔室頂板 210‧‧‧Cable ceiling
212‧‧‧電漿處理區域 212‧‧‧The plasma processing area
214‧‧‧發光設備 214‧‧‧Lighting equipment
220‧‧‧收光設備 220‧‧‧Lighting equipment
222‧‧‧透鏡 222‧‧‧ lens
240‧‧‧RF電源供應器 240‧‧‧RF power supply
280‧‧‧控制器 280‧‧‧ Controller
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